Note: Descriptions are shown in the official language in which they were submitted.
CA 02689011 2009-12-30
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SOLUBLE OAT OR BARLEY FLOUR AND METHOD OF MAKING
UTILIZING A CONTINUOUS COOKER
FIELD OF THE INVENTION
[0001] The present invention relates generally to soluble oat or barley flour.
More
specifically, the present invention relates to methods of making soluble oat
or barley
flour.
BACKGROUND
[0002] Oatmeal has for many years been a staple of the human diet due to its
health
benefits. For example, numerous studies have shown that eating oatmeal on a
daily basis
can help lower blood cholesterol, reduce risk of heart disease, promote
healthy blood
flows as well as maintain healthy blood pressure levels. Additionally, oatmeal
has high
content of complex carbohydrates and fibers, which facilitates slow digestion
and stable
blood-glucose levels.
[0003] With today's hectic lifestyle, consumers are demanding convenience,
such as
portability and ease of preparation. Consumers desire oatmeal from a variety
of food
sources including beverages, and convenience foods such as bars, cookies,
crackers,
smoothies, and the like.
[0004] It is desired to prepare a whole oat product that has sufficient
soluble fiber to
meet the FDA threshold necessary to justify a health claim. For example, a
whole oat
product must have 0.75 g soluble beta-glucan fiber per serving of food. To
prepare an oat
beverage that contains at least 0.75 g soluble oat fiber per serving (about 18
g of whole
grain oats), highly soluble oat flour must be used. Traditionally, highly
soluble flour is
prepared using enzymes such as a-amylase. The enzyme-treated oat flour is then
drum or
spray dried. This method takes place in at least two steps and is
traditionally expensive
and produces the soluble oat flour in low rates. For example, a slurry batch
is prepared of
flour (oat) and water (70-90% moisture content). Enzyme (s) are then added to
the slurry
and held at optimum enzyme reaction conditions followed by enzyme deactivation
process. The slurry is then transferred into either a spray or drum drier.
More efficient
processes are desired to prepare the oatmeal product.
CA 02689011 2012-03-30
[0005] Likewise, barley has become a desired staple of the human diet for
health
reasons and suitable means to process and prepare barley containing products
is desired.
SUMMARY
[0006] Aspects of the present invention relate to preparing soluble oat or
barley flour
in one-step using an extrusion (continuous cooking) process to gelatinize and
dextrinize
the oat flour.
[0007] These and other aspects, along with advantages and features of the
present
invention herein disclosed, will become apparent through reference to the
following
description. Furthermore, it is to be understood that the features of the
various
embodiments described herein are not mutually exclusive and can exist in
various
combinations and permutations.
[0007.1] According to one aspect of the present invention there is provided a
method of producing a soluble whole oat or barley flour comprising forming a
whole oat
or barley flour starting mixture comprising whole oat or barley flour,
granulated sugar,
and at least one antioxidant; hydrating the starting mixture to a moisture
content of 25 to
35 wt% and heating to a temperature of 140 to 160 F; adding the hydrated
heated whole
oat or barley flour starting mixture in an extruder; gelatinizing and
dextrinizing the whole
oat or barley flour by mechanical action and heating of the extruder to form
to form
extruded pellets; dehydrating the extruded pellets and granulating to form the
soluble
whole oat or barley flour having a size of 50 to 250 microns.
[0007.2] According to a further aspect of the present invention there is
provided a
method for preparing a beverage containing a soluble whole oat or barley flour
comprising: forming a whole oat or barley flour starting mixture comprising
whole oat or
barley flour, granulated sugar, and at least one antioxidant; hydrating the
starting mixture
to a moisture content of 25 to 35 wt% and heating to a temperature of 140 to
160 F;
adding the hydrated heated whole oat or barley flour starting mixture in an
extruder;
gelatinizing and dextrinizing the whole oat or barley flour by mechanical
action and
heating of the extruder to form extruded pellets; dehydrating the extruded
pellets and
granulating to form the soluble whole oat or barley flour having a size of 50
to 250
microns; and adding the soluble oat flour to a beverage.
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[0007.31 According to another aspect of the present invention there is
provided a
method for preparing a food product containing a soluble whole oat or barley
flour
comprising: forming a whole oat flour starting mixture comprising whole oat or
barley
flour, granulated sugar, and at least one antioxidant; hydrating the starting
mixture to a
moisture content of 25 to 35 wt% and heating to a temperature of 140 to 160 F;
adding
the hydrated heated whole oat or barley flour starting mixture comprising
whole oat or
barley flour, granulated sugar, and at least one antioxidant in an extruder;
gelatinizing
and dextrinizing the whole oat or barley flour by mechanical action and
heating of the
extruder to form extruded pellets; dehydrating the extruded pellets and
granulating to
form the soluble whole oat or barley flour having a size of 50 to 250 microns;
and adding
the soluble oat flour to a mixture for a food product.
DETAILED DESCRIPTION
100081 The present invention relates to soluble oat or barley flour and a
method of
producing soluble oat or barley flour using a continuous cooker to gelatinize
and
dextrinize whole oat or barley flour in one step. The process is easier, less
expensive,
and less time-consuming than prior art processes.
[00091 A starting mixture is prepared containing whole oat or barley flour,
granulated
sugar, optionally a maltodextrin, and at least one antioxidant.
[00101 The whole oat or barley flour is present in an amount of about 50% to
about
100% by weight of the total weight of the starting composition. In further
aspects, the
whole oat or barley flour is present in amounts of about 80 % to about 100% by
weight or
about 90% to about 95% by weight.
[00111 The sugar can be any suitable sugar known to those skilled in the art.
Non-
limiting examples of sugars include sucrose, fructose, dextrose, other sugars
known in the
art, and combinations thereof. Typically, the sugar is present in an amount of
about 0 to
about 15% by weight of the total weight of the starting composition. In
further aspects,
the sugar is present in amounts of 0 to about 7% by weight.
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[0012] The maltodextrin may be present in an amount of about 0% to about 15%
by
weight of the total weight of the starting composition. In further aspects,
the
maltodextrin is present in amounts of about 3% to about 7% by weight.
[0013] The antioxidant may be any suitable antioxidant such as mixed natural
tocopherols or artificial antioxidant such as BHT and BHA. The antioxidant is
present in
an amount from 0.1 % to 2 % by weight. In further aspects, the antioxidant is
present in
amounts of about 0.25 % to about 0.75 % by weight.
[0014] The mixture may be pre-hydrated in a preconditioner prior to extrusion.
It is
well known in the industry that pre-conditioners can aide in reducing the
required
mechanical power of the extruder to cook the mixture. The pre-conditioner will
give an
overall increase in throughput. In the pre-conditioner, water or steam is
added to increase
the moisture content of the mixture to about 25 to about 35%, more
specifically about 28
to about 30%. The mixture's overall temperature is increased to about 140 IF -
160 F
prior to extrusion. The mixture has the characteristics of a uniform free
flowing wetted
material prior to extrusion.
[0015] Starch gelatinization requires water and heat. The gelatinization
temperature
range for oats is 127 F to 138 OF (53 - 59 C). If the moisture is less than
about 60%
then higher temperatures are required. Typically the extrusion occurs at
barrel
temperatures between 140 OF and 250 OF. The dough temperatures are
approximately 212
OF and 260 OF.
[0016] The mixture is fed into the extruder. Any suitable extruder may be used
including suitable single screw or twin screw extruders. Typical, but not
limiting, screw
speeds are 200-300 rpm.
[0017] For example, a hydrated mixture at a temperature of about 140 F -160
F is
fed into a low-shear cooking extruder. Low-shear cooking extrusion is defined
by a
moisture range of 20 to 35%, a shear rate range of 20 to 100 s-1, mechanical
energy input
of 0.02 to 0.05 kw-hr/kg and maximum dough temperature less than or equal to
150 C.
Extrusion of Foods by Judson M. Harper CRC Press 1980
[0018] Heat may be applied through the extruder barrel wall such as with a
jacket
around the barrel through which a hot medium like steam, water or oil is
circulated, or
electric heaters imbedded in the barrel. Heat is also generated within the
material by
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friction as it moves within the extruder. Shear is controlled by the design of
the extruder
screw(s) and the screw speed. Viscosity is a function of starch structure,
temperature,
moisture content, fat content and shear. The shear stresses and heat applied
in the
extruder to the starches, especially the amylopectin, reduce their average
molecular
weight.
[0019] The extruded dough exits the cooking extruder. As it exits, water
immediately
evaporates cooling the dough and dropping its moisture content into the 25 to
30% range.
The dough is then fed into a second forming extruder where it is further
cooled below the
boiling point of water, forced through a die opening and cut into pellets. The
25 to 30%
moisture pellets are then transported to a pellet drier and de-hydrated to
approx 7-10%
moisture; specifically 8-9%. The pellets may then be granulated. Granulation
specifications can be widened. 50-250 microns. Specifically, targeting 178-250
micron;
maximizing. 212 microns
[0020] The granulated product may be used in beverages such as ready-to-drink
beverages, fruit juices, dairy beverages, and carbonated soft drinks, and
various food
products such as bars, cereals, puddings, smoothies, powdered beverages,
cookies,
crackers, and the like. The soluble oat flour can also be used to make soft
food products
such as ice cream and soft yogurt. This list is not all-inclusive and one
skilled in the art
would recognize that the soluble oat flour may be added to other beverages and
food
products in accordance with the invention.
[0021] A beverage, for example, contains from about 1% to about 25% soluble
oat or
barley flour and from about 70% to about 95% total water, typically about 75%
to about
90%, by weight of the total beverage. The balance can contain sweeteners,
flavors, fruits
and other materials as desired.
[0022] The water should be suitable for use in food. The total water may come
in part
or in whole from other parts of the drinkable food, especially if milk,
juices, or other
water containing components are used. For instance, the milk may be dairy
(e.g. whole,
2%,1 %, or non-fat) or non-dairy (e.g. soy). The milk may also be produced
from
powdered milk and water.
[0023] The beverage may also include a fruit component. The fruit component
can
include fruit juice, yogurt containing fruit, fruit puree; fresh fruit, fruit
preserves, fruit
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sorbet, fruit sherbet, dried fruit powder, and combinations thereof.
Typically, the fruit
component has particles sufficiently small that the component may be safely
swallowed
without chewing. The fruit component and/or an added acidulant can be adjusted
to
obtain a desired pH, for example a pH of less than about 4.6.
[00241 Food products include cereals and ready-to-eat snack bars. A suitable
amount
of the granulated product is added to the food mixture.
[00251 Additional ingredients may be added to the beverage and food products.
Such
ingredients can include non grain-based ingredients. For example, flavoring
agents,
coloring agents, sweeteners, salt, as well as vitamins and minerals can be
included. In
one embodiment of the invention, flavoring agents such as strawberry,
chocolate or
cinnamon flavor is added to enhance the taste of product. Other fruit
flavoring agent may
also be useful to provide different tastes to the food product, for example,
strawberry,
mango and banana and mixtures thereof. Spices, in particular, cinnamon, can be
used. In
addition, any desired flavor or flavors can be used. Suitable sweeteners -
artificial or
natural can be added in the food product to provide a desired sweetness. For
example,
brown sugar, maple sugar or fruit sugar can be used. The non-grain based food
component can be added in the range of about 10 to 75 wt % of the total weight
of the
product.
[00261 Other optional ingredients, but are not limited to, salt,
hydrocolloids,
polysaccharides, thickeners, caffeine, dairy, coffee solids, tea solids,
herbs, nutraceutical
compounds, electrolytes, vitamins, minerals, amino acids, preservatives,
alcohol,
colorants, emulsifiers, and oils as known in the art.
[0027] The soluble oat or barley flour includes beta glucan soluble fiber,
such as
beta-1, 3-glucan, beta-1, 6-glucan, or beta-1, 4-glucan or mixtures thereof.
In addition to
beta glucan naturally present in the oats, beta glucan may also be added as
approved by
the FDA. In certain embodiments, the oat flour preferably contains at least
about 3% to
5% or about 3.7% to 4% beta glucan. In certain embodiments, the oat flour
containing
liquid product contains 0.1 % to about 1.5% beta glucan, or about 0.8% to 1.3%
beta
glucan. Other amounts of beta glucan are also useful.
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[0028] As described, the present invention provides a healthy drinkable food
product
which is easy and quick to prepare while convenient to consume on-the-go,
making it
especially appealing to consumers with today's hectic lifestyle.
[0029] Example 1
[0030] A flour mix formula for extrusion process
Ingredient %
Whole oat flour 86.5
Sugar 5
Maltodextrin 5
Mixed tocopherols 0.5
Waxy com starch 3
Total 100.00
[0031] Example 2
[0032] A cracker formula is typically made from whole wheat flour or wheat
gluten.
Instead the formula would be replaced with this hydrolyzed oat flour to
improve
nutritional benefits (heart health) as well as provide adequate strength to
the dough be
sheeted and cut into crackers. The formula would include:
Modified com starch 10.00
Oat flour, Hydrolyzed 48.00
Oat flakes, old fashioned 17.00
Brown sugar, free-flowing 12.00
Malt powder, Briess #10001 4.00
Lecithin, powdered, Centrolex F 2.00
Sodium aluminum phosphate 0.80
Sodium bicarbonate 0.70
Salt, flour 0.60
Corn Oil, with TBHQ ADM 5.00
Total 100.00
[0033] Example 3
[0034] A formula for oat ice cream
Ingredient %
2% Milk 87.0
Oat flour, hydrolyzed 6.5
Sugar 5.4
Cocoa powder 0.8
Flavor 0.2
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Modified starch 0.1
Total 100.0
100351 The scope of the claims should not be limited by the preferred
embodiments
set forth in the examples, but should be given the broadest interpretation
consistent with
the description as a whole.
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